No-sew non-woven utility bag

ABSTRACT

A utility bag using molded and/or extruded frames is covered with a poly-type laminate material. The laminate is attached using an adhesive or other non-sewn fastening techniques so to construct a soft-sided utility bag or container having at least four sides and a bottom. The bag is lightweight, durable and breathable, yet resistant to water, abrasion, bacterial penetration and aging while being inexpensive to manufacture.

FIELD OF THE INVENTION

The present invention relates generally to utility bags and more particularly to a soft-sided utility bag made of non-woven materials and having a no-sew construction.

BACKGROUND

Woven polyester utility bags are well known in the art and are often used to carry food products, small transportable items and sometimes small appliances. These bags can be made of polyester or other woven material which make them strong and light weight however, the processes to manufacture them is often expensive and time consuming. Much of the manufacturing expense of the utility bag is related to sewing and hemming material edges to prevent the material from unraveling with use. Most often, these small utility bags use a combination of materials such as foil, foam and fabric that require cutting and sewing the materials to facilitate their construction. This manufacturing process adds cost to the product because of the labor and machinery involved. Accordingly, new solutions are required to manufacture utility bags in a more cost-effective manner.

BRIEF DESCRIPTION OF THE FIGURES

The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the present invention.

FIG. 1 and FIG. 2 are elevated perspective view of a non-woven utility bag.

FIG. 3 is a top view of the bag shown in FIG. 1 and FIG. 2.

FIG. 4 is a bottom view of the bag shown in FIG. 1 and FIG. 2.

FIG. 5 a side view of the bag shown in FIG. 1 and FIG. 2.

FIG. 6 is an exploded view of the bag shown in FIG. 1 and FIG. 2.

Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the present invention.

DETAILED DESCRIPTION

Before describing in detail embodiments that are in accordance with the present invention, it should be observed that the embodiments reside primarily in combinations of method steps and apparatus components related to a no-sew, poly material utility bag. Those skilled in the art will recognize that the poly-material as used in the invention can be cut to exact size requirements making it very useful for tighter tolerance projects. Due to its non-woven nature, the edges do not require the application of welting cord or hemming in order to avoid fraying typically associated with woven fabrics. Accordingly, the apparatus components and method steps have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

In this document, relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

FIG. 1 and FIG. 2 are elevated perspective views of a non-woven utility bag having a no-sew construction according to an embodiment of the invention. FIG. 3 is a top view of the bag shown in FIG. 1 and FIG. 2. FIG. 4 is a bottom view of the bag shown in FIG. 1 and FIG. 2. FIG. 5 is a side view of the bag shown in FIG. 1 and FIG. 2. FIG. 6 is an exploded view of the bag shown in FIG. 1 and FIG. 2. With regard to each of FIGS. 1-6, the utility bag 100 includes a top frame 101, bottom frame 103 and lid frame 105. Each frame can be made of inexpensive molded or extruded plastics or other rigid or semirigid, lightweight materials having square of rounded corners. The bottom frame 103 is typically dimensionally larger and wider than the top frame 101 and lid frame 105 since it supports the bag as well as its contents when the bag is lying on a flat surface. In addition to plastic extrusions, the frame may also be fabricated using various injection molding techniques in order to make a strong yet inexpensive support frame used for forming and supporting the overall bag shape.

Although shown in a substantially square shape, those skilled in the art will recognize that other bag shapes are also possible. In order to form an enclosed bag, a strong sheet-like cover material such as non-woven or spun-bound poly material. In one example, polypropylene plastic or the like can be used. In other embodiments, the cover material may be PVC, Styrofoam, metallic materials or combinations thereof that can also work to contain heat generated within the bag. Materials of this nature are lightweight, durable and breathable, yet resistant to water, abrasion, bacterial penetration and aging. These materials offer many advantages including their ability to use digital print upon the material surface using various ink colors, logos and/or other indicia. Moreover, these poly materials can be a single type of material of construction or they may also form part of a laminated material having several layers e.g., an inner bag surface of foil aluminum, a middle layer of insulating foam, and an outer layer of poly material.

During construction, a bead of glue or other adhesive or mechanical fastener can be applied to portions of each respective frame of the utility bag. The glue works to adhere each respective covering surface to its respective frame. For example, a first covering sheet formed from one contiguous sheet of cover material forms the lid 107, back side 109 and bottom 111 of the bag 100. This first sheet is cut to size, wrapped and glued to each of the top frame 101 and bottom frame 103 and lid frame 105. In alternative embodiments, the first covering sheet can have its edges wrapped and fastened around the various frames.

Similarly, a second contiguous sheet of material is cut and sized to form each of the sides of the bag 100 i.e., the left side 113, front side 115 and right side 117. The second contiguous sheet of material is then covered and/or wrapped around the edges to enclose the sides of the bag 100. The second contiguous sheet of material is also glued or otherwise mechanically fastened to the frame components as described herein. Since the lid frame 105 is positioned below the lid 107, the lid 107 can close and fit snuggly within the top frame 101.

Since zippers can be expensive and are generally sewn onto surface material, the lip 107 instead can be held closed with Velcro or other types of inexpensive snaps or mechanical fasteners. Those skilled in the art will further recognize that since the first sheet of material is strong and pliable, it works also to hinge 119 the lid 107 to the bag allowing it to open and close repeatedly without tearing. Although not shown, loops or other carry handles can also be glued to surfaces of the bag for easy carrying and transport.

Thus, the present invention is directed to a non-woven, no-sew utility bag. The construction of the utility bag uses non-woven materials that require no sewing of the plastic sheet material. Various components used in the bag can be easily glued or otherwise attached or fastened to the support frames at a greatly reduced manufacturing expense while still providing an attractive and durable utility bag.

In the foregoing specification, specific embodiments of the present invention have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the present invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of present invention. The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential features or elements of any or all the claims. The invention is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued. 

We claim:
 1. A utility bag comprising: a top frame, bottom frame and lid frame; a first sheet of non-woven material forming a bottom, back and lid of the bag; a second sheet of non-woven material forming a left side, front side and right side of the bag; and wherein the first sheet of material is adhered to the top frame, bottom frame and lid frame to form a bottom side, back side and lid of the bag and the second sheet of material is adhered to the top frame and bottom frame to form a left side, front side and right side of the bag.
 2. A utility bag as in claim 1, wherein the frame is a plastic formed using extrusion or injection molding techniques.
 3. A utility bag as in claim 1, further comprising: a fastener for joining the lid to the front side of the bag for holding the lid in a closed position.
 4. A utility bag as in claim 1, where the non-woven material is a spun-bound polyethylene fiber.
 5. A utility bag as in claim 1, wherein the bag is substantially square in shape.
 6. A utility bag comprising: a plurality of plastic frames; plastic sheet like poly-material covering the plurality of rigid frames; an adhesive or other non-sewn material fastening the plastic sheet to the plurality of rigid frames; and wherein the plurality of rigid frames are configured to construct a container with at least four sides and a bottom.
 7. A utility bag as in claim 6, further comprising: a lid; a front side, back side, top side and bottom side; and wherein a fastener is configured to join the lid to the front side of the bag for holding the lid in a closed position.
 8. A utility bag as in claim 6, wherein the rigid frame is formed using extrusion or injection molding techniques.
 9. A utility bag as in claim 8, wherein the rigid frame is a plastic material.
 10. A utility bag as in claim 6, where the plastic sheet is a spun-bound polyethylene fiber.
 11. A utility bag as in claim 6, wherein the container is substantially square in shape.
 12. A utility bag comprising: a top frame; a bottom frame; a first sheet of non-woven material for joining the top frame and bottom front so to form a left side, front side and right side of the utility bag; a lid frame; a second sheet of non-woven material for forming a lid, back side and bottom of the utility bag; and wherein the top frame and bottom frame are joint to the lid frame with the second sheet of non-woven material to form the utility bag.
 13. A utility bag as in claim 12, further comprising: a fastener for joining the lid to the front side of the bag for holding the lid in a closed position.
 14. A utility bag as in claim 12, wherein the frame is plastic formed using extrusion or injection molding techniques.
 15. A utility bag as in claim 12, where the non-woven material is a spun-bound polyethylene fiber.
 16. A utility bag as in claim 12, wherein the bag is substantially square in shape. 